Process of fusing thermoplastic fabric sheets to each other



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J. CADGENE Filed June 17, 1949 Jan. 13, 1953 PROCESS oF FUSING THERMOPLASTIC FABRIC SHEETS To EACH OTHER F/l i Patented Jan. 13, i953 UNITED STATES PATENT PROCESS oF FUSING THE-RMoPL-ASTrc FABRIC SHEETS 'ro `EACH OTHER jJacques Gadgene, PatersomN. J.

Application J une, 1949, vS eralNofQS (Cl. l'15d- 75) Claims. l

'My present invention relates to processes :of

applyingto the surface f of -a fabric -or A.part ithere'of aplastic-coating material. r`ltfis'anobject cf my presen-t invention to-'rmly apply-a plastic maten-alto the surface Aor `par-t of the surface of Aa fabric in L'an 'extremely simple Way.

It is a further object of my present invention tacarry-eutabove` process-1in an rinexpensiveimanner-'Withoutcomplicatedfmachines involving-Iconsiderable expenses.

Anotherfo'bj eetof `-Inylpresent inventionconsists in #fusing two fabrics at least onelof which ,consists -o'f 'thermoplastic yarns Por lafmentspermanently `to each other.

EVS7-ith the f-above objects in view, `my presentinvention mainly consists :in .a process `of'fusing to at least part of the surface oifla fabric consisting of a material having a certain melting point a plastic coating material having a lower melting point than the material of which 'said fabric'fconsists, thefprocess comprising the step of Lpassin'g the fabric `with the 'plastic 'coating .material applied` to -at least part of its Isurface through-ta heated bath :of lmolten Vmetal .having :a 'temperature insuiiicient to 'melt the .material ogf the fabric consists but sufcient to at leastfpartly` melt fthe plasticcoatingmaterial sofas torfuse the sameto the fabri'c.

The plastic coating material is preferably :a thermoplastic substance such as resins, certain cellulose acetates, and glass compositions.

The `fabric to which fthe thermoplastic-coating material is. applied might consist also fof ,aplastic material such as gla's's; however, it .hasta have., as setv forth above, a .meltingr 'point which higher, preferably :substantially higher, than'the melting point of the .plastic :coating-:material tto be applied.

My present process Vis also veryl well adapted forfusing to .the surface of a rstfabriclasecond fabric consisting .of a. plastic material having -a melting point not. exceeding v`the melting point lof the material of which the first fabric fconslsts, the. process comprising the step of jpa'ssing the fabrics superimposed upon each other through a heated bath of molten metal having a temperature sucient to plasticize the plastic material of which the second fabric -consistsiso as -tov fuse the same to the first fabric.

In this event, it is advisable to :press thefftwo fabrics during their passage through the heated bath of molten metal against each other sofas -to ensure proper contact and `consequent.complete fusing.

In accordance with my present invention, it is also xpossibleltofusetwo :thermoplastic `fabrics =to each '.other; *this particular process :includes `4the step of .passi-ngV the V'thermoplastic 'fabrics superimposed .upon each other -through :a heated :bath of :molten metal hav-ing a temperature suicie-nt to plasticize the plastic material off Awhich at least onefo'f the fabricsnconsists .so as to 4fuselthe thermoplafstic fabricsto .each other.

0f course, it is .possible :to `make ltwo thermos plastic :fabrics of `plastic laments 'or g-yarns :having substantially the'same melting vpoi-nt; Vin `this event, bothfabrics will be plasticized andr-mly adhere `tof-each other.

In general, 'the time of passage of the fabric or fabrics through the metal 'ba-th depends upon they type lof plastic material -of Vwhich the `plastic coatings and/or plastic .fabrics cons-ist. Of course, :the :temperature fof the `metal bath is also to :be take-n into Yconsideration `when determining the time `of immersion of the Afabric or :fabrics into the bath. Nevertheless, it Vn1-ight be stated that infgenera-l the time :of treatment, i. e.'immersion into the metal bath, `var-ies between three and :sixty gsecends, depending upon the above listed variousconditions iniiuencing the `treatment.

.lt has been ioundthatthe -suriaceo-f.a.mol=ten metal 'bath has thevtendency to -oxidize and cause formation of ame-tal oxide layer on the .surface of 'the molte-n metal. InV .order `fto avoid -such Oxide --layer v*which -`adversely aifects .the treated fabrics, .it is advisable to fprovide `a .zone of inert gas, at least at those surface portions of the metal bath .where the-:fabrics .enter andlleave ,the hathysoas 'to .prevent adherenceof oxides 'tothe sur-'face of the trea'tedfabrics. Reducing .,gase's, Such 4as carbon monoxidepare particularly well adapted for vthe .purposes of .my present invention.

'Thenovel features which I consider as characteristics for my invention are set forthfi-n'particular in the appended claims. The invention itself, however, both as to its constructionaand its method fof operation, together 'with additional objects fand advantages thereof, wiil bebestzunderstood` fromthe following :description of specific emb'odinients'wlien read in; connection with :th-eaccmirpanyingA drawings, :in which:

zllig. f1 x'is la .schematic cross section throughva metal-,bath arrangement adapted Afor. the-purposes of fmypresent invention; .and

Fig. 2 is a schematic showing of a modied metal .bath .arrangement similar to the oneslio'wn in Fig. Yibut equipped with ,a ,pressureroller The arrangement shown in 'Figure 1 'consistsof a vessel I0 made of a heat insulating material-in which the 'electric heating coils 'I l 'are embedded.

This vessel I is partly filled with a molten metal alloy I2, heated by means of the heating coils II.

The vessel is closed on its top by a cover I3 provided with two slots I4 and I5. The fabric I6 with the plastic coating material I6 applied thereto enters the vessel through slot I4, passes over the first metallic supporting roller II, engaging face I8 of the fabric, and over the second metallic supporting roller I9, engaging the face 20 of the fabric. Then the fabric I6 passes over the guiding roller 2I and is pulled out of the metal bath through the outlet slot I by means of the take-up roller 22 exerting tension on the fabric in direction of arrow 23.

It should be noted that it is of great importance that the metal rollers I'I and I9 engage both faces I8 and 20, respectively, of the fabric I6, as otherwise the metal particles o f the metal bath I2 are unable to properly penetrate and affect all filaments of the fabric. This seems to be due to the fact that air particles are caught between the filaments preventing access of the molten metal to the surface of all filaments and that these air particles are removed by passage of the fabric over the rollers Il and I9.

It is evident that during passage of the fabric I6 with a plastic coating material I6 applied thereto through the metal bath I2 the plastic coating material I6 will melt and be firmly fused to the filaments of the fabric I6, as intended in accordance with my present invention.

The space 24 within the vessel I0 above the surface 25 of the metal bath I2 is preferably filled with a reducing gas, e. g. by introducing through conduit 26 carbon monoxide, preventing formation of an oxide film on the surface 25 of the bath. In order to control the presence of monoxide in the treating vessel, I have found it advisable to provide in the surface of the vessel a small exit opening 21 provided with a valve 28. The monoxide escaping through this opening is lighted and burns with a small flame 29. As long as this flame 29 is visible, there is carbon monoxide in the treating vessel and no danger of formation of an oxide film exists.

The arrangement shownin Figure 2 is very similar to the arrangement shown in Figure 1; the only difference is that two fabric sheets 30 and 3i enter the vessel I0 through slot I4 and pass the metal bath I2 superimposed upon each other so as to be fused to each other, as set forth above in detail.

Furthermore, in this embodiment of my present invention, I provide an additional pressure roller 32 arranged as shown, and cooperating with the rst roller Il so as to compress the fabric sheets 30 and 3| and thereby assist in fusing them to each other.

My new processes are carried out in the following way:

First, the vessel I0 is filled with a metal or metal alloy having a low melting point. Eutectic metal alloys are particularly well adapted for my purposes. Thus, I have found that alloys composed of cadmium, antimony and lead furnish a very good bath. Similarly, lead, tin, cadmium and similar alloys, such as bismuth, tin, lead alloys, are very well adapted as metal bath compositions.

Then, the vessel I0 is heated by means of the heating coils II until the desired metal bath is formed.

Thereafter, a reducing gas, such as carbon 4 monoxide, is introduced through conduit 2B. valve 2u is opened, and flame 29 is lighted.

The apparatus is then ready for operation and the fabric with the coating material applied thereto or the two fabrics to be fused to each other are then passed through it so as to immerse into the bath for a time period of between three and sixty seconds.

Several examples of my new process are described below without, however, limiting the scope of my present invention to the particular compositions and conditions set forth in the same:

Example I A cotton fabric with thermoplastic coating material, e. g. vinyl resin, applied to its surface is passed through a metal bath consisting or' 60% of lead, 20% of tin, and 15% of cadmium. The temperature of this metal bath is maintained at between 115 and 130 C. The speed of movement of the fabric is regulated so that it immerses into the bath for between ten to twelve seconds.

During this treatment, the vinyl resin is plasticized, while the cotton fabric remains unchanged. The plasticized vinyl resin adheres then as required to the filaments of the cotton fabric.

Example II A glass fabric consisting of glass having a high melting point with part of its surface covered with a glass composition having a low melting point is passed through the bath of the above described composition. This bath is kept at a temperature which is above the melting point of the glass coating composition and below the melting point of the glass fabric itself. This treatment will result in fusing of the glass coating composition to the glass fabric.

Example III A cotton fabric and a fabric consisting of a cellulose acetate are passed superimposed upon each other through a metal bath consisting of about 28% of bismuth, 48% of tin, and 34% of lead, kept at a temperature of about 110 C. so that they immerse into this bath for about thirty seconds.

During this treatment, the cellulose acetate fabric will be plasticized and will firmly adhere to the cotton fabric.

Example IV A glass fabric and a fabric consisting of vinyl resin filaments are passed in superimposed condition through a bath of the type described in Example I having a temperature sufficient to slightly plasticize the vinyl resin. The resulting composite fabric consists of the glass and resin fabrics firmly adhering to each other.

It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of fusing processes, differing from the types described above.

While I have illustrated and described the invention as embodied in processes for fusing thermoplastic coating materials to fabrics and' fusing thermoplastic fabrics to each other, I do not intend to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of my invention.

Without further analysis, the foregoing will so fully reveal the gist of my invention that others can by applying current knowledge readily adapt it forvarious applicationsA without' omitting features that, vfrom the standpoint :of prior art, fairly constitute essential characteristics-of the generic or specific aspects of this invention, and, therefore, such adaptations should and are intended to be'comprehended within the meaning and range of equivalence-of the following claims.

'What I claim as new and desire -to secure'by Letters Patent is:

1 'Process of fusing to the surface of `afirst fabric strip a second fabric strip consisting of a plastic 'material having a melting point Abelow that vof `the first fabric strip, Usaid process-comprising the steps'of continuously inserting said fabriclstripswhile maintaining the same spaced from-each other individually into Va'h'eated bath of molten metal having a temperature-suflcient to plasticizeonly the yplastic materialfof Awhich said second fabric strip consists, thereby eliminating adhering air from Asaid fabric strips while said strips are maintained spaced from each other in said `heated bath ofmolten metal; continuously moving said fabric strips along a predetermined path in said bath; superimposing said moving fabric strips upon each other within said bath of molten metal so as to fuse said plasticized second fabric strip to said first fabric strip; and continuously withdrawing 'saidfused fabric strips from said bath of molten metal.

2. Process of fusing to the surface of a first fabric strip a secondfabric strip consisting of a plastic material having a melting point below that of the'first fabric strip, said process comprising the steps of continuously inserting said fabric strips'while maintaining the same spaced from each vother individually into a heated bath of moltenmetal having a temperature sufficient to plasticize only the plastic material of which said second fabric strip consists, thereby eliminating adhering air from said fabric strips while said strips are maintained spaced from each other in said heated bath of molten metal; continuously moving said fabric strips along a predetermined path in said bath; pressing said moving fabric strips together within said bath of molten metal so as to fuse said plasticized second fabric strip to said first fabric strip; and continuously withdrawing said fused fabric strips from said bath of molten metal.

3. Process of fusing to the surface of a rst fabric strip a second fabric strip consisting of a thermoplastic material having a melting point below that of the first fabric strip, said process comprising the steps of continuously inserting said 'fabric strips while maintaining the same spaced from each other individually into a heated bath of molten metal having a temperature sucient to plasticize only the thermoplastic material of which said second fabric strip consists, thereby eliminating adhering air from said fabric strips while said strips are maintained spaced from each other in said heated bath of molten metal; continuously moving said fabric strips along a predetermined path in said bath; superimposing said moving fabric strips upon each other within said bath of molten metal so as to fuse said plasticized second fabric strip to said first fabric strip; and continuously withdrawing said fused fabric strips from said bath of molten metal.

4. Process of fusing thermoplastic fabric strips to each other, said process comprising the steps of continuously inserting said fabric strips while maintaining the same spaced from each other individually into a heated bath of molten metal having a temperature` Isumcient to 1 plasticize fat least one of saidfabric strips, thereby eliminating adhering Vair from said fabric strips Awhile said strips are maintained spaced from each other in said heated bath of molten-metal; continu- 'ously Amoving said fabric vstrips along a predetermined path in said bath; superimposing'said moving fabric `stripsupon each other `Awithin said bath of molten -metal so v-as to fuse said fabric strips together; and continuously withdrawing said fused fabric strips'from saidbath ofmolten metal.

`5. Process of fusing thermoplastic fabricy strips to-each other, said process` comprising the steps ofcontinuously insertingsaid fabric strips while 4maintaining the same'spaced rfrom each -other individually into a heatedbathV of moltenmetal having a temperature sufficientto-plasticize Ysaid fabric strip, thereby eliminating adhering `air from said fabric strips while said strips "are maintained spaced from each other in said-heated bath of molten metal; continuously'movingisaid fabric strips along apredetermined path in said bath; pressing said moving fabric stripstogether within said bath of molten metal sofas to fuse said plasticized fabricstrips to each other; and continuously withdrawing said fusedfabric strips from saidbath of molten metal.

6. Process of fusing to the surfacelof a first fabric strip asecond fabric strip consisting .of fa plastic material having a melting point'below that ofthe first fabric strip, vsaid process comprising the steps of preparing a heated bath of molten metal having a temperature sufcient'to plasticize only the plastic material of which said second fabric strip consists; maintaining'anl inert gas-at the surface of said metal bath to prevent oxidation of the molten metal at said surface; continuously inserting said fabric strips while maintaining the same spaced from each other individually into said heated bath of molten metal, thereby eliminating adhering air from said fabric strips while said strips are maintained spaced from each other in said heated bath of molten metal; continuously moving said fabric strips along a predetermined path in said bath; superimposing said moving fabric strips upon each other within said bath of molten metal so as to fuse said plasticized second fabric strip to said first fabric strip; and continuously withdrawing said fused fabric strips from said bath of molten metal.

7. A process of fusing to the surface of a first fabric strip a second fabric strip consisting of a plastic material having a melting point below that of the first fabric strip, said process comprising the steps of continuously inserting said fabric strips while maintaining the same spaced from each other individually into a heated bath of molten metal having a temperature sufficient to plasticize only the thermoplastic material of which said second fabric strip consists, thereby eliminating adhering air from said fabric strips while said strips are maintained spaced from each other in said heated bath of molten metal; continuously passing said fabric strips over a first roller in said molten metal bath contacting one of said fabric strips to superimpose the moving fabric strips upon each other for fusing the plasticized second fabric strip to said lrst fabric strip and for removing air from between the yarns of said one fabric strip; continuously moving said fabric strips from said first roller over a second roller contacting the other of said fabric strips to remove air from between the yarns thereof;

asomo? and continuously withdrawing said fused fabric strips from said molten metal bath.

8. A process of fusing to the surface of a first fabric strip a second fabric strip consisting of a plastic material having a melting point below that of the `first fabric strip, said process comprising the steps of continuously inserting said fabric strips while maintaining the same spaced from each other individually into a heated bath of molten metal having a temperature sufficient 'to plasticize only the thermoplastic material of which said second fabric strip consists, thereby eliminating adhering air from said fabric strips while said strips are maintained spaced from each other in said heated bath of molten metal; continuously passing said fabric strips between and in contact with a pair of rollers in said molten metal bath to superimpose the moving fabric strips upon each other for fusing the plasticized second fabric strip to said rst fabric strip and for removing air from between the yarns of said fabric strips; and continuously withdrawing said fused fabric strips from said molten metal bath.

9. Process of fusing thermoplastic fabric strips to each other, comprising the steps of continuously inserting said fabric strips While maintaining the same spaced from each other individually into a heated bath of molten metal having a temperature sufficient to plastioize at least one of -said fabric strips, thereby eliminating adhering air from said fabric strips while said strips are maintained spaced from each other in said heated bath of molten metal; continuously passing said fabric strips over a first roller in said molten metal bath contacting one of said fabric strips to superimpose the moving fabric strips upon each other for fusing the same to each other and for removing air from between the yarns of said one fabric strip; continuously moving said fabric strips from said first roller over a second roller contacting the other of said fabric strips to remove air from between the yarns thereof; and continuously withdrawing said fused fabric strips from said molten metal bath.

10. Process of fusing thermoplastic fabric strips to each other, comprising the steps of continuously inserting said fabric strips While maintaining the same spaced from each other individually into a heated bath of molten metal having a temperature sufficient to plasticize said fabric strips, thereby eliminating adhering air from said fabric strips while said strips are maintained spaced from ecah other in said heated bath of molten metal; continuously passing said fabric strips between and in contact with a pair of rollers in said molten metal bath to superimpose the moving fabric strips upon each other for fusing the plasticized second fabric strip to said nrst fabric strip and for removing air from between the yarns of said fabric strips; and continuously withdrawing said fused fabric strips from said molten metal bath.

JACQUES CADGENE.

REFERENCES CITED The following references are of record in the nie of this patent:

UNITED STATES PATENTS Number Name Date 1,801,396 Thatcher Apr. 21, 1931 2,399,258 Taylor Apr. 30, 1946 2,431,050 Koppln Nov. 18, 1947 2,468,656 DeForest Apr. 26, 1949 2,522,346 Carson et a1 Sept. 12, 1950 

1. PROCESS FOR FUSING TO THE SURFACE OF A FIRST FABRIC STRIP A SECOND FABRIC STRIP CONSISTING OF A PLASTIC MATERIAL HAVING A MELTING POINT BELOW THAT OF THE FIRST FABRIC STRIP, SAID PROCESS COMPRISING THE STEPS OF CONTINUOUSLY INSERTING SAID FABRIC STRIPS WHILE MAINTAINING THE SAME SPACED FROM EACH OTHER INDIVIDUALLY INTO A HEATED BATH OF MOLTEN METAL HAVING A TEMPERATURE SUFFICIENT TO PLASTICIZE ONLY THE PLASTIC MATERIAL OF WHICH SAID SECOND FABRIC STRIP CONSISTS, THEREBY ELIMINATING ADHERING AIR FROM SAID FABRIC STRIPS WHILE SAID STRIPS ARE MAINTAINED SPACED FROM EACH OTHER IN SAID HEATED BATH OF MOLTEN METAL; CONTINUOUSLY MOVING SAID FABRIC STRIPS ALONG A PREDETERMINED PATH IN SAID BATH; SUPERIMPOSING MOVING FABRIC STRIPS UPON EACH OTHER WITHIN SAID BATH OF MOLTEN METAL SO AS TO FUSE SAID PLASTICIZED SECOND FABRIC STRIP TO SAID FIRST FABRIC STRIP; AND CONTINUOUSLY WITHDRAWING SAID FUSED FABRIC STRIPS FROM SAID BATH OF MOLTEN METAL. 